Spray drying process and apparatus



July 8, 1958 M. BALLESTRA SPRAY DRYING PROCESS AND APPARATUS 2 SheetsqSheet 1 Filed Aug. 29, 1952 R m m .El w I I -I i h A A A m L @A @WSR A. nu Sv. SN Sw S Wm S @i .www 4 :uw w \N` N\\ M.\\ N V 18N QQ U :v1/l :L A C lv @S L A w Q DI X S m Q NN Z I\H J t v Af: ,l A i A A w\\ S u SS Sm AS A A A ,A A RQ L. SSSQS NS MARIO BALLESTRA ATTORNEY July 8, 1958 M. BALLESTRA SPRAY DRYING PROCESS AND APPARATUS 2 Sheets-Sheet 2 Filed Aug. 29, 1952 INVENTOR. BALLESTRA MARIO A TTORNE Y Patented July 8, 1958 SPRAY DRYING PROCESS AND APPARATUS Mario Ballestra, Genoa, Italy Application August 29, 1952, Serial No. $117,112

Claims priority, application Italy December 13, 1951 5 Claims. (CI. 159-4) The present invention relates to the spraying of :1 slurryI or solution, particularly a soap or detergent, in a cylindrical chamber. The spray in finely divided form come,` in contact with heated air or gas blown into the chamv ber. In spraying plants of this type there is a producticml of hollow particles by a rapid drying of the treated ma" terial. Known plants of this type have serious drawbacks especially with respect to the formation of fines. due :o the difficulty or the impossibility of regulating the drying process and of treating materials which are much affected by temperature, etc., und therefore of acting on the qual ities of the product.

The present invention relates to a spraying chamber and particularly to an apparatus for drying, Yrnmilatingj crystallizing and solidifying solutions or slurries. partir-ularly of soaps, detergents, synthetic detergents and every l;

material which can be produced in solid form from in solutions or slurries; as well as solutions or slurries el' crystallizable materials or products having a solidificatiovl point higher than the temperature of the air which is used for refrigeration.

The basic characteristics of the present invention are:

The spraying chamber has a conical upper end in which is placed a first, upper hood whose walls are parallel to the conical walls of the chamber. inside the upper hood are placed the ducts for the drying or treating air or gm. which is generally at high temperature but essentially' at a controlled temperature, and the spraying nozzles. Sturt@ for air at a controlled temperature or suction ducts are placed in the top of the conical upper end of the chamber. In the upper end of the chamber are :also placed spraying nozzles of the pressure type and of the two-huid type with controlled air temperature. The cylindrical spraying chamber has spraying nozzles near the` upper end thereof which are directed downward and inward tnngentially of the axis of the chamber. so that the paths of the sprays lie substantially wholly beneath the lower edge of the upper conical hood. The chamber is provided with at least one distributor of air or gas lo ted between the top and the bottom of the tower. The air or gas ducts are provided with the usual devices for regu-A 5 i loting the pressure and the temperature of the gas. The bottom of the spraying chamber is in the form of a cone. at the end of which the sprayed particles are discharged continuously. At the base of this conical bottom of the tower are located air or gas distributors. Near the bottom of the tower a second, lower conical hood with the large base towards the base of the chamber, is located. The lower conical hood is designed to diminish the crosssection of the tower, and therefore to restrict the tlow passage of the air and sprayed particles in the lower end zone of the chamber.

The various air or gas distributors, located inside the tower, can also acts as air or gas suction ducts. The lower conical hood located in the conical bottom of the spraying chamber is provided with special devices which may be operated to produce a reduction in pressure inside the hood and to allow the withdrawing or exhausted air and line particles produced in the spraying process by suction.

The circulating gas or air is supplied in a closed systern which consists of a conventional oil burning furnace, several fans either for the spraying air, or for the treating air or gas, regulating devfces for controlling the temperature and pressure of said air or gas, cyclone dust collectors for separating the fine particles from the spent treating air or gas, and a refrigerating unit for cooling the air or gas from the chamber.

The chamber, in one particular application, has its lower end in direct connection with the outside, either through the discharge duct, or through openings located in the conical wall.

Moreover the spraying apparatus is furnished with a perfuming unit, which operates directly on the sprayed product before its discharge from the spraying chamber.

Referring to the drawings:

Fig. l is a somewhat schematic view in elevation of u preferred form of the apparatus in which the process ot" the present invention can be successfully conducted.

Fig. 2 is an enlarged fragmentary view in vertical axial section through the upper end of the spraying chamber and the upper conical hood positioned therein, certain parts of the apparatus being shown in elevation.

Fig. 3 is an enlarged fragmentary view in vertical axial section through the lower end of the spraying chamber and the lower conical hood positioned therein, certain parts of the apparatus being shown in elevation.

Fig. 4 is a fragmentary horizontal section through the upper end of the spraying chamber, the section being taken generally along line X-X of Fig. 2, the upper conical hood and its attendant parts being omitted for simplicity of illustration.

The material to be handled is blended in special mixers l, is pumped by means of a pump 2 through a filter unit 3 and by means of another pump 4 to the nozzles 8 through conduits 50 and 121, where it comes iu con* tact with compressed air blown by an air compressor 16 through preheater 29 and conduit 51 to branch conduits 122 connected to nozzles 8. The spraying chamber l l has in its upper part a zone 26 where air inlets are lo cated. Under this zone the chamber has the form of u truncated cone in which there is located one coaxial conical hood 10. The nozzles 8 are located in a position to spray under the lower edge of the cone 10. Inside thc cone 10 is located at least one nozzle 9 fed with the material to be sprayed under the pressure of the pump 4 through conduit S0 and branch conduit 52.

A furnace 5 provides hot gases which are discharged through a conduit 53 having a valve 130 therein to branch conduits 54 and S5 leading, respectively, to driven blowers 6 and 7. Conduits 54 and 55 are provided with selectively operated valves 141 and 142` respectively'. Beyond the intersection between branch conduit S3 with conduits 54 and 55, a further conduit 56 is provided with valve 129 for exhausting to the atmosphere. Between the intersection of conduit 53 with conduits 5-1 and 55 and the respective blowers 6 and 7, two branch pipes 143 and 144, provided with valves 112 and 113, respectively. are connected to the atmosphere. By means of said pipes 143 and 144 it will be possible to mix a predetermined desired proportion of cold air with the hot gas discharged by furnace 5.

Hot gas from the furnace, or a mixture thereof with cold air, as described, is discharged centrally within the upper end of hood 10 through conduit 57 and a nipple 58 attached to the hood. Such hot gas, or a mixture thereof with cold air, is also introduced into the upper zone of the chamber through distributor 26. or in the middle zone of the chamber through distributor' 22: or in the lower zone of the chamber near the junction otv the cylindrical wall with the conical bottom 24 by the distributor 23.

The annular distributor 26, which is disposed ahorny nipple S8, has a screen-like bottom 115 through which air is discharged to the space between the con.' il u ver i.) end of chamber 1l and upper hood lil, Distributor La is supplied with gas by discharge conduit 59 irri-.m blower 7. Conduits 59 and 57 are connected by crots-cuuluia. 103 and 145, as shown. Valves ltlS and l-lt in crm.- conduits 103 and 145 allow to be delivered i" "1 tributor 23 whiie the ilow of gas to distribuir; 26 is shut off. Additional valves 6d to di' are di on the conduits as shown in the drawings. T". th'.` conduit 59 is provided with a valve 60 between the inlet to distributor 23 and the intersection with cro 14S, a valve 61 is disposed in conduit S7 lac junctions with cross-conduits 103 and 1451,` the ini't `rw outlet to distributor 23 are provided with valves di; le. t 63, respectively, the inlet and outlet to distributor 22. un; provided with valves 64 and 65, respectively, and th ill inlet and outlet to distributor 26 are provided v. ith valve 66 and 67, respectively.

The duct 25 is connected with the perfuming unit 14. The inlet air distributors 26, 22 and 23 are con".` teil through suction ducts 126, 127 and 128, rcsjrezti.' ,i a cyclone dust separator unit 17 which is in cycle with the suction fans 6, 7 through the t'an 2t? and un uil' reir erating unit 21. unit 21 selectively delivering rclrig` r air through conduit 132 to the intake conduit 53 for blowV ers 6 and 7. As shown, a valve 131 is disposed in con 119 duit 132 and conduit 132 connects` beyond valve l5! with conduit S3 above valve 130 in the latter conduit. Thus the intake conduit for blowers 6 and 7 may selectively supplied with hot gases from furnace or with refrigerated air from unit 21. The cyclone scplr 35 rators 17 are also connected with the vertex of conc 12, located in the interior of the conical bottom 24 of the chamber. The lower edge of said cone 12 is located t a predetermined distance from the interior wall of thc conical bottom 24 of the spraying chamber. Thisy conw 4U ical bottom has several openings 27 and a collecting draht pipe 28.

Various manners of flow of hot or cooled gases hun the apparatus may be attained b v varying the setting o? the valves 112. 133. 129,13@ t3. it? ard N12: 5

l. When valves 131 and 1.29 are closed and valves 112 and/or 113 are closed, valves 141 and 142 lacing open. hot air is fed to blowers 6 and 7.

2. When valve 13] is closed and valves 112, H3. and 130 are opened (valves 1l2 and 113 being opened to f1. 5l) predetermined desired degree) with valves tdi und M2 also being open. hot air mixed with a predetermined proportion of cold atmospheric air is fed to blowers n and 7.

3. When valves 130 and 131 are closed and valves 1l?. and 113 are opened the desired amount, cold :atmospheric air is fed to blowers 6 and 7, valves 141 und i442 also being open.

4. When valves 112, 113 and 130 are closed and vulve 131 is opened. refrigerated air is fed from unit 2l through lil) conduits 132 to the blowers 6 and/or 7, depending upon the status of valves 141 and 142.

5. By suitably regulating valves 130, 131. Ml. 142. 112 and 113 hot. cool, or refrigerated air or gas can he supplied to blowers 6 and/or 7. 65

With the present spraying plant it is possible. by the usr. of special regulating devices, to obtain ditiercnt produit. and to conduct different processes, viz.:

(a) Instant drying and cooling in counter-current zur;

(b) Gradual drying in countercurrent nir throughout T0 a part of the tower height and countercurrcut cooling:

(c) Gradual drying in concurrent air throughout the total height of the tower and countercurrent cooling in the discharge cone;

(d) Gradual drying in concurrent air throughout thc total height of the tower or part of it, with the possibility of regulating the temperature of the diierent zones of the tower;

(e) Partial instant drying, stoppage of the drying, and cooling in countercurrent throughout the total height oi the tower;

(f) Cooling and crystallization, either in concurrent or in eountercurrent;

(g) Initial cooling for partial crystallization, drying zuid cooling;

(l1) Cooling of materials having a melting point above the temperature of the refrigerated air in the cyrlc, with the production of solidified granulated products.;

(i) Mixing, inside the spraying chamber, of the sprayed or crystallized product with powdered material-s, by means of a special proportioning device which dclivers the material directly onto the product cooled but not yet solidified; and

(j) Continuous perfuming of the sprayed product by means of nozzles located in the discharge cone.

The above processes are realized by regulating the` pressure of the air in the nozzles 8, the pressure of the material fed to the nozzles 9, the pressure of the air blown in the zone 23, the temperature of said air and said inaterial, the vacuum produced in the lower part of the spraying chamber by the fan 20 through the cyclone 17. etc. For carrying out operation (i), there is shown in Fig. l a feeding valve D having a rotor C provided with peripheral notches N rotating in the direction of the larrow f discharging through outlet duct d into the hopper h of a duct c into which is introduced compressed air in the direction of the arrow f" for conveying measv ured portions of material which are supplied from the hopper H in the direction of the arrow F. Duct e dis4 charges into three branch ducts p, p' and p" controlled by valves K, K' and K", respectively, and these duct.v terminate in nozzles n, n,' and n" which extend into the interior of the spray channel 11 at vertically spaced apart points.

In the spraying chamber there can be successive zones of concurrent and counter-current hot or cold air, and it is possible to obtain a great variety of dried products from the same initial slurry, that is products of different granulation and bulk density.

The suction cone 12, situated in the discharge cone 24 of the chamber, is located at a height which allows a good separation by centrifuging of the sprayed product from the drying or cooling air, by means of the acceleration given to the particles from the increased speed of the air in correspondence with the diminished section of the free etucnce and the sudden change of direction.

In the case of the production of hollow beads, their separation from the fines is accomplished by means of cold air in countercurrent. The granulated product is discharged through the duct 25, While the lines float in the air and are removed together with the exhausted air and recovered by the cyclone separators 17. The discharge of the sprayed product is continuous and autornatic.

The upper double cone allows the blowing through its vertex of very hot air or gases, which cause the explosion or the formation of hollow particles from the material blown through the nozzles 9 soon after the hollow particles come in contact with the air at a lower temperature which is blown through the head 26 of the chamber.

In this way the chemical alteration of the heat sensitive products is avoided. The lower cone 12 with central suction, produces the separation of the lines, either by the greater speed of motion of the product in the opening of the cone 12, or by said suction action, and the hollow particles fall to the bottom. By means of the vacuum produced in the lower part of the cone 24, cold air enters through openings 27 and rises in countercurrent, causing the further cooling of the hollow particles and the complete separation of the fines.

The material which, due to improper operation of the nozzles, may drop along the walls of the cone 24, is discharged through the opening,` 27, thus avoiding its falling on the nal product. The closed circuit cycling of the air sucked by the cyclone 17, and the presence of the refrigerator 21, allows the solidiiications of particles in said closed circuit at a lower temperature than that of the surroundings and avoids evaporation of water present in the material.

Typical specific examples of use of the apparatus among those indicated above, are carried out as follows:

1. Instant drying and cooling in countercurrent air In this use of the apparatus, heated air from furnace 5 is introduced into distributor 23. Valves 60, 63, 112, 131 are closed, and valves 113, 142, 62, 130 are open. To such air, which passes upwardly in chamber 11 and meets the sprays of material from nozzles 8 and 9, is added cold atmospheric air entering through openings 27. The air is exhausted from chamber 11 through conduits 126 and 120; valve 67 is open.

2. Gradual drying in countercurrent air through a prtion of chamber or tower height, and countercurrem cooling In this use of the apparatus heated air from furnace is introduced into chamber 11 through distributor 22; valves 130, 142, 113, 60, 64 are open; the other valves are closed. Cold atmospheric air is added thereto by flow into the chamber 11 and then upwardly therein, through openings 27. Air is exhausted from the chamber as in (l) above; valve 67 is open.

3. Gradual drying in concurrent air through the total height of the chamber and countercurrent cooling in the discharge zone Heated air is introduced into chamber 11 through distributors 22 and 26; valves 130, 142, 113, 60, 64, 141, 112, 61 are open; the other valves are closed. Valve 141 is open so that such heated air is discharged by blower 6 to hood 10. Valve 67 is open.

The manner of operation of the apparatus in each of the other indicated methods of its use will readily be apparent from the above. Thus, for example, when the apparatus is operated to give partial instant drying, stoppage of the drying, and cooling in countercurrent through the total height of the chamber or tower; valves 113, 62, 105, 141, 112, 66 and 65 are open; the other valves are closed; cool air is introduced into the chamber by distributor 23, warm air is introduced by distributor 26, and the cool and warm air are exhausted through distributor 22.

When the material is cooled and crystallized in concurrent air, valves 112, 105 and 66 are open', the other valves are closed; cool air is introduced into the top of the chamber at nozzles 8 and distributor 26 and is exhausted by hood 12 through conduit 120. When a countercurrent is desired in such process; the valves 113 and 62 are open and additional cool air may be introduced through distributor 23. For initially cooling the material for partial crystallization, drying and cooling valves 112, 105, 66, 130, 142, 113, 60 and 64 are open; the other valves are closed; cool air is introduced through distributor 26 and warm air is introduced through distributor 22, air being exhausted from hood 12 through conduit 120.

The invention includes many modifications and par ticulars not set forth in the foregoing description which is given only by way ot' example taken in connection with the preferred form of apparatus shown in the enclosed drawing.

What I claim is:

1. An apparatus for spray drying solid materials associated with a liquid medium which comprises, in combination, means defining a vertical chamber, means communicating with the upper portion of the chamber for introducing the material to be spray dried into the upper portion of said chamber, means for conducting air into the chamber to impinge upon and thereby disperse said material as it is introduced into the chamber, means for selectively supplying heated air and atmospheric air to said chamber for contact with the material being spray dried, a rst distributor in the upper portion of said chamber, a second distributor in the lower portion of said chamber, and a third distributor intermediate said first and said second distributors, said three distributors being connectable with said means for selectively supplying heated air and atmospheric air, exhaust means for removing air and gaseous products from said chamber, said exhaust means being connectable to said three distributors, whereby air and gaseous products may be intro-duced and may be withdrawn selectively through said distributors.

2. An apparatus for spray drying solid materials :is` sociated with a liquid medium which comprises, in combination, means defining a vertical chamber, means communicating with the upper portion of the chamber for introducing the material to be spray dried into the upper portion of said chamber, means for conducting air into the chamber to impinge upon and thereby disperse said material as it is introduced into the chamber, means for selectively supplying heated air and atmospheric air to said chamber for contact with the material being spray dried, a rst distributor in the upper portion of said chamber, a second distributor in the lower portion of said chamber, and a third distributor intermediate said rst and said second distributors, said three distributors being connectable with said means for selectively supplying heated air and atmospheric air, exhaust means for removing air and gaseous products from said chamber, said exhaust means being connectable to said three dis tributors, whereby air and gaseous products may be in troduced and may be withdrawn selectively through said distributors, the upper portion of said chamber being cunical and having disposed within it a concentric hollow conical baie member, the means for introducing into the chamber the material to be treated being located inA teriorly of said cone and the means for introducing the dispersing gas directing it in at least one jet having c. path mainly below the base of said cone, the rst disiributor being positioned to discharge the drying gas into the annular space between the exterior surface of the conical baie and the interior surface of the conical top of the chamber.

3. An apparatus for spray drying solid materials associated with a liquid medium which comprises, in combination, means defining a vertical chamber, means communicating with the upper portion of the chamber for introducing the material to be spray dried into the upper portion of said chamber, means for conducting air into the chamber to impinge upon and thereby disperse said material as it is introduced into the chamber, means for selectively supplying heated air and atmospheric air to said chamber for contact with the material being spray dried, a first distributor in the upper portion of said chamber, a second distributor in the lower portieri of said chamber, and a third distributor intermediate said first and said second distributors, said three distributors being connectable with said means for selectively sup plying heated air and atmospheric air, exhaust means for removing air and gaseous products from said chaml ber, said exhaust means being connected to said three distributors, whereby air and gaseous products may be introduced and may be withdrawn selectively through said distributors, the lower end of the chamber being in the shape of an inverted cone and having an upright hollow conical member disposed interiorly thereof, the vertex of said conical member being connected to said exi haust means, whereby gases are withdrawn from the lower end of said chamber through said conical member.

4. An apparatus for spray drying solid materials as soci' teli with u liquid medium which comprises, in combinati means dening a vertical chamber, means communitning with the upper portion of the chamber for introducing the material to be spray dried into the upper portion ot' said chamber', means for conducting air intsF the f' `mbcr to impinge upon and thereby disperse said mutA l is it is introduced into the chamber, means for selec t supplying heated air and atmospheric air to said :rl-:sauber for contact with the material being spray dried, ,i rst distributor in the upper portion of said chambsr, u second distributor in the lower portion of said chamber, and a third distributor intermediate said lit-sl ,rn-J said sefond distributors, said three distributors being co *recta i with said means for selectively sup dying he. d `tir und atmospheric air, exhaust means for removing air and gaseous products from said chamber', said exhaust means being connectable to said three distributors. Anhcrcby air and gaseous products may be i11- troduccd and may be withdrawn selectively through said distributers. the lower end of the chamber being in the shape tu" un inverted cone and having an upright hollow conical member disposed interiorly thereof, the vertex ot' wat unical "rcrnbcr being connected to said exhaust nrcan vliet-clay g es are Withdrawn from the lower end nl' sind chamber through said conical member, said lower end et aid chamber being provided with openings` tor admission ot' the air surrounding the chamber, id openings being disposed below the base of said con icul member.

5. An apparatus for spray drying solid materials associated with u liquid medium which comprises, in cornhinlrtiun. means defining vertical chamber, means communicuti ith the upper portion of the chamber for intrsdu material to be spray dried into the up per pu 'tw nl ssid chamber, means for conducting air into the chamber to impinge upon and thereby disperse said material as it is introduced into the chamber, means tor selectively l pplying heated air and atmospheric air cr Contact with the material being spray to said chamber dried. u first distributor in the upper portion of said chamber, second distributor in the lower portion of 45 said chamber, and a third distributor intermediate said first and said second distributors, said three distributors being connectable with said means for selectively supplying heated air and atmospheric air, exhaust means vlor removing air and gaseous products from said chamber, .said exhaust means being connectable to said three distributors, whereby air and gaseous products may be introduced and may be withdrawn selectively through said distributors, the upper portion of said chamber be- `r::il and having disposed within it a concentric cui. al bathe member, the means for introducing into the chamber the material to be treated being located interiorly of said cone and the means for introducing the dispcrsiug gas directing it in at least one jet having a path mainly below the buse of said cone, the first distributor being positioned to discharge thc drying gas into thc annular spuce between the exterior surface of the conical bulilc and the interior surface of the conical top of the chamber, the lower end of the chamber being in the .shape of an inverted cone and having an upright hollow conical member disposed interiorly thereof, the vertex of said conical member being connected to said exhaust means whereby gases are withdrawn from the lower und of said chamber through said conical member, said lower end of said chamber being provided with openings l or admission of the air surrounding the chamber, said openings being disposed below the base of said conical member.

im; ct,

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